Surface material substrate, surface material and molded body

Abstract

A surface material substrate has one surface of a fiber substrate containing cellulosic fiber is bonded with an acrylic resin binder containing a flame retardant and a thermosetting resin, a fineness of fiber constituting the fiber substrate is 2.2 dtex or less, and a mass ratio of the acrylic resin to the thermosetting resin is 80:20 to 65:35. A surface material is provided with an adhesive layer containing a resin with a melting point of 200° C. or less on a surface of the fiber substrate of the surface material substrate opposite to a facing surface, which is bonded with the acrylic binder. In a molded body, the surface material is integrated with a substrate mat by heat molding via an adhesive layer. The surface material substrate simultaneously fulfills requirements of low weight and cost, design properties, flame retardancy, mold releasability, followability and trimming properties.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to a substrate for a surface material, to a surface material and to a molded body. More specifically, it relates to a surface material substrate, surface material and molded body with excellent design properties, flame retardancy, mold releasability, followability and trimming properties, which can be used favorably as a surface material substrate, surface material and molded body for automotive applications.[0003]2. Related Background Art[0004]Conventionally, needle-punched nonwoven fabric impregnated with vinyl chloride binder, acrylic binder or polyester binder has been used as surface materials for automobile insulators (Patent Documents 1 to 4). Such a surface material is molded as a unit with a substrate mat consisting of resin felt, cardboard, plastic foam, fiberglass resin composite, wood stock or rigid nonwoven fabric for use in various automotive parts. One method of molding such ...

AI Technical Summary

Benefits of technology

The present invention provides a surface material substrate that fulfills requirements of low weight, low cost, design properties, flame retardancy, mold releasability, followability, and trimming properties. The substrate contains cellulosic fibers and a flame retardant in the acrylic resin binder, and also contains a thermosetting resin. The acrylic resin binder contains a thermosetting resin and has a mass ratio of 80:20 to 65:35, which provides excellent trimming properties and prevents the surface material from sticking during trimming. The substrate has high design properties, sound absorption, and can be integrated with a substrate mat by using an adhesive layer during heat molding. The molded body using this surface material exhibits superior flame retardancy, mold releasability, surface quality, and sound absorption.

Problems solved by technology

However, in cases where the basis weight of the substrate for a surface material proposed by the applicants of the present application has been reduced in order to achieve weight and cost reductions in recent years, when the substrate for a surface material is molded as a unit with a substrate mat, the surface material becomes transparent and the substrate mat shows through, detracting from the design properties.

This was successful in terms of preventing transparency, but created a new problem in terms of trimming properties, perhaps due to the fineness of the fibers and the thinness of the surface material substrate.

This solved the trimming problem, but created a new problem of poor mold releasability due to the increased amount of binder.

Thus, it has been difficult to simultaneous achieve low weight and cost while providing good design properties, flame retardancy, mold releasability, followability and trimming properties with conventional surface material substrates.